Thanks for the reply, YMMV.
I knew this project wouldn't be cheap, so I'm cool with spending a few bucks. Learning how to do the work is more important to me than the final product.
I'll worry about finish on the next project.
To give you a point of reference, I've managed to remove most of the cowl dents, floorboard waves, and legshield bends through trial-and-error, watching Restolad and such. Also, did a complete disassembly of the bike using the Darnell and Golfen book. Luckily, I had enough foresight to buy a project with a running engine. So, this rust is really my last scary hurdle to having a decent ride.
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I am going to assume that a sharp pointed awl would break thru at some of the places I see in the picture.
Would an awl be a good litmus test? That is, if the awl doesn't poke though and the steel has some thickness left, then it's okay structurally. Or, should I be overly pessimistic about it and cut-and-weld regardless?
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If I were doing this I would Cut and weld in metal where needed then have the frame media blasted, treated with a rust killer and then primed with a epoxy based primer (DP40). The end product will depend on your skill level, available tools and of course the patience to finish the job.
Tools I have... welder, grinder, dremel, you name it (Thanks, Dad). I do not have skillz though. I've taken a basic welding/metal shaping class, but that's it. I figured this would be a good real-world learning experience.
My current plan is to stitch weld using a 1mm thick steel patch. I am also planning to MIG weld (Lincoln 135 / Maybe using shielding gas?). I'm not sure what type of wire to use though... I've been told that a thin brass wire is the right choice. Does this all sound reasonable?
